Golf club head structure for improving casting fluidity in a slurry shell

ABSTRACT

A golf club head structure includes a first portion and a second portion adjacent thereto. The first portion and the second portion have a first thickness and a second thickness respectively. The ratio of the first thickness to the second thickness ranges between 0.56 and 1.00 that may enhance casting fluidity of molten iron in a slurry shell to thereby reduce the possibility of generating contraction cavities and slag-eyes in the golf club head.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a golf club head structure for improving casting fluidity in a slurry shell. More particularly, the present invention relates to a golf club head structure consisting of two adjacent portions having changes in thickness to improve casting fluidity in a slurry shell and casting quality.

2. Description of the Related Art

Fe—Mn—Al alloy has highly low density, excellently vibration-absorbable and high degree of hardness. Casting a golf club head with Fe—Mn—Al alloy, the center of gravity of the golf club head may be lowered, and a striking surface area and dimensions of the golf club head may be increased. In slush casting, inevitably, when Fe—Mn—Al alloy is employed to cast a casting of a golf club head, a finished product of the casting has many casting deficiencies of cold-shot, contraction cavities and slag-eye due to low casting fluidity in a slurry shell. Generally, the improvement of casting technology and cast molding system may eliminate deficiencies of cold-shot and slag bonding. As to the contraction cavity, a finishing and grinding process can eliminate it. However, when the contraction cavities are located in a complicated structure and an unbalanced thickness (such as an opening or an undercut) of the golf club head, it is hard to eliminate the contraction cavities by means of the finishing and grinding process. Consequently, the contraction cavities may be remained on the surface of the golf club head that may result in a decrease in the value of products. Thus, the applied scope of Fe—Mn—Al alloy in the industry is restricted and unsuitable for casting the golf club head. Hence, there is a need for a club head structure which is suitable for using Fe—Mn—Al alloy in slush casting.

The present invention intends to provide a golf club head structure for a casting consisting of two adjacent portions having changes in thickness to improve casting fluidity in a slurry shell and casting quality. In slush casting, the ratio of width of the slurry shell allows the fluent passage of molten iron of Fe—Mn—Al alloy to eliminate contraction cavities and slag-eyes in a casting in such a way to mitigate and overcome the above problem.

SUMMARY OF THE INVENTION

The primary objective of this invention is to provide a golf club head structure for improving casting fluidity in a slurry shell. The golf club head structure consists of two adjacent portions having changes in thickness corresponding to changes in width of the slurry shell to thereby avoid generating contraction cavities and slag-eyes in a casting.

The golf club head structure in accordance with the present invention includes a first portion and a second portion adjacent thereto. The first portion and the second portion have a first thickness and a second thickness respectively. The ratio of the first thickness to the second thickness ranges between 0.56 and 1.00 that may enhance casting fluidity of molten iron in a slurry shell to thereby reduce the possibility of generating contraction cavities and slag-eyes in the golf club head.

Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described in detail with reference to the accompanying drawings wherein:

FIG. 1 is a cross-sectional view of a golf club head structure for improving casting fluidity in a slurry shell in accordance with a first embodiment of the present invention;

FIG. 2 is an enlarged cross-sectional view, in FIG. 1, of the golf club head structure in accordance with the first embodiment of the present invention;

FIG. 3 is a cross-sectional view of the slurry shell for the golf club head structure in accordance with the first embodiment of the present invention;

FIG. 4 is an enlarged cross-sectional view, in FIG. 3, of the slurry shell for the golf club head structure in accordance with the first embodiment of the present invention;

FIG. 5 is a lateral schematic view of a golf club head structure for improving casting fluidity in the slurry shell in accordance with a second embodiment of the present invention;

FIG. 6 is an enlarged lateral view, in FIG. 5, of the golf club head structure in accordance with the second embodiment of the present invention;

FIG. 7 is a cross-sectional view of a golf club head structure for improving casting fluidity in the slurry shell in accordance with a third embodiment of the present invention; and

FIG. 8 is enlarged cross-sectional view, in FIG. 7, of the golf club head structure in accordance with the third embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring initially to FIGS. 1 through 4, a golf club head structure in accordance with a first embodiment of the present invention includes a club head body 10 pertaining to an iron-type club head integrally formed with a single member and made of Fe—Mn—Al alloy. The single member of the club head body 10 includes an annular flange 11, a flat plate portion 12, a weight portion 13 and a compartment 14. In assembling, the compartment 14 is adapted to receive a weight member 15 for adjusting a center of gravity of the club head body 10. Each of the club head sections has two adjacent portions gradually changing in thickness, a connecting portion of the flat plate portion 12 to the annular flange 11 or the flat plate portion 12 to the weight portion 13 for example.

Referring again to FIG. 3, a slurry shell 20 can be made by dewaxing a wax pattern (not shown) of the club head body 10. The construction of the slurry shell 20 has a cavity 21 configured with an inner space corresponding to an outer predetermined shape of the club head body 10. Consequently, the club head body 10 can be obtained by pouring molten iron of Fe—Mn—Al alloy into the cavity 21 of the slurry shell 20.

Referring back to FIGS. 2 and 4, in slush casting, the club head body 10 should avoid generating contraction cavities and slag-eyes in a casting formed in the cavity 21 of the slurry shell 20. To accomplish this task, the cavity 21 of the slurry shell 20 has two adjacent portions with respect to a reference point (shown at “a”) changing in width. The ratio of the two widths of the any two adjacent portions ranges between 0.56 to 1.00 that may improve casting fluidity in the slurry shell 20.

Referring again to FIG. 2, a boundary between the flat plate portion 12 and the annular flange 11 of the club head body 10 has changes in thickness. The flat plate portion 12 has a thickness t1 (a thinner thickness) while the annular flange 11 having a thickness t2 (a thicker thickness). As best shown in FIG. 4, the cavity 21 of the slurry shell 20 correspondingly includes a first width t1 (a thinner width) and a second width t2 (a thicker width). The ratio of the first width t1 to the second width t2 of the cavity 21 ranges between 0.56 and 1.00. In slush casting, molten iron of Fe—Mn—Al alloy may fluently pass through any two adjacent portions of the cavity 21 of the slurry shell 20 since the cavity 21 has such changes in width for enhancing casting fluidity of molten iron. Consequently, the structure of the club head body 10 accomplishes to enhance casting fluidity of Fe—Mn—Al alloy that further carries out to avoid generating contraction cavities and slag-eyes in the club head body 10 and to improve casting quality.

Referring back to FIG. 4, the thickness of the annular flange 11, the flat plate portion 12, the weight portion 13 and the compartment 14 preferably ranges from 2 mm to 6 mm and more preferably from 2 mm to 4 mm, excluding the hosel (not labeled). Consequently, such thickness can reduce the possibility of generating contraction cavities and slag-eyes in the club head body 10.

By contrast, the conventional club head body is made of stainless steel having density of 7.8 g/cm³. The club head body 10 in accordance with the present invention is suitable for Fe—Mn—Al alloy having lower density of 6.8 g/cm³ that can reduce 15% of weight and further lower a center of gravity. To adjust a center of gravity, the weight member 15 (density of 10.0 g/cm³) received in the compartment 14 is added for maintaining total weight of the club head body 10.

In consideration of the thickness ranging from 2 mm to 6 mm, the club head body 10 is unsuitable for press-fitting or snap-fitting the weight member 15 into the compartment 14. To prevent deformation and cracks of the club head body 10, the weight member 15 preferably connects to the compartment 14 of the club head body 10 by welding. In welding process, the present invention employs a nickel-welding material and a current of a welding torch preferably ranges from 100 A to 150 A that may improve heterogeneous-weldable characteristic.

Turning now to FIGS. 5 and 6, reference numerals of the second embodiment of the present invention have applied the identical numerals of the first embodiment. The construction of the golf club head member in accordance with the second embodiment of the present invention has similar configuration and same function as that of the first embodiment and detailed descriptions may be omitted.

Referring to FIGS. 5 and 6, a golf club head structure in accordance with a second embodiment of the present invention includes a club head body 10 pertaining to a pitching wedge or a sand wedge integrally formed with a single member and made of Fe—Mn—Al alloy. In comparison with the first embodiment, the club head body 10 of the second embodiment includes a flat plate portion 12 and a weight portion 13. A thickness of the club head body 10 preferably ranges from 2 mm to 17 mm, excluding the hosel (not labeled). As best shown in FIG. 6, a boundary between the flat plate portion 12 and the weight portion 13 of the club head body 10 has changes in thickness. There exists a reference point (shown at “a”) changing in thickness for enhancing casting fluidity in a slurry shell (not shown). The flat plate portion 12 has a thickness t1 (a thinner thickness) while the weight portion 13 having a thickness t2 (a thicker thickness). The ratio of the first thickness t1 to the second thickness t2 ranges between 0.56 and 1.00. In slush casting, molten iron of Fe—Mn—Al alloy may fluently pass through any two adjacent portions of the cavity of the slurry shell. Consequently, such thickness can reduce the possibility of generating contraction cavities and slag-eyes in the club head body 10. In particular, the entire weight portion 13 of the club head body 10 has any two adjacent portions to confine changes in thickness ranging between 0.56 and 1.00.

Turning now to FIGS. 7 and 8, a golf club head structure in accordance with a third embodiment of the present invention includes a club head body 30 pertaining to a wood-type club head formed with a single member and made of Fe—Mn—Al alloy. In comparison with the first embodiment, the club head body 30 of the third embodiment consists of a main body 31, a front opening 32 and a stepped portion 33, and the front opening 32 is adapted to connect to a striking plate (not shown). A thickness of the club head body 30 preferably ranges from 1 mm to 3 mm, excluding the hosel (not labeled). As best shown in FIG. 8, a boundary between the main body 31 and the stepped portion 33 of the club head body 30 has changes in thickness. There exists a reference point (shown at “a”) changing in thickness for enhancing casting fluidity in a slurry shell (not shown). The stepped portion 33 has a thickness t1 (a thinner thickness) while the main body 31 having a thickness t2 (a thicker thickness). The ratio of the first thickness t1 to the second thickness t2 ranges between 0.56 and 1.00. In slush casting, molten iron of Fe—Mn—Al alloy may fluently pass through any two adjacent portions of the cavity of the slurry shell. Consequently, such thickness can reduce the possibility of generating contraction cavities and slag-eyes in the club head body 10.

To prevent deformation and cracks of the club head members, the thiner stepped portion 33 of the club head body 30 connects to an outer periphery of a striking plate by welding instead of press-fitting the striking plate into the front opening 31.

In slush casting, the conventional structure of the club head casting in Fe—Mn—Al alloy results in generating contraction cavities and slag-eyes. However, the golf club head in accordance with the present invention has any two adjacent portions having changes in thickness to improve casting fluidity in a slurry shell and casting quality.

Although the invention has been described in detail with reference to its presently preferred embodiment, it will be understood by one of ordinary skill in the art that various modifications can be made without departing from the spirit and the scope of the invention, as set forth in the appended claims. 

1. A golf club head made of Fe—Mn—Al alloy, comprising: a club head body having at least two adjacent portions located at a reference point; the two adjacent portions having a first thickness and a second thickness with respect to the reference point; the ratio of the first thickness to the second thickness ranging between 0.56 to 1.00 that improves casting fluidity of molten iron of Fe—Mn—Al alloy to reduce the possibility of generating contraction cavities and slag-eyes in slush casting;
 2. The golf club head as defined in claim 1, wherein the club head body is an iron-type club head.
 3. The golf club head as defined in claim 2, wherein the club head body has a thickness ranging from 2 mm to 6 mm.
 4. The golf club head as defined in claim 2, wherein further comprising a weight member welding to the club head body.
 5. The golf club head as defined in claim 1, wherein the club head body is a pitching wedge or a sand wedge.
 6. The golf club head as defined in claim 5, wherein the club head body has a thickness ranging from 2 mm to 17 mm.
 7. The golf club head as defined in claim 1, wherein the club head body is a wood-type club head.
 8. The golf club head as defined in claim 7, wherein the club head body has a thickness ranging from 1 mm to 3 mm. 